Ultrasonic Transducer Assembly and System for Monitoring Structural Integrity

ABSTRACT

In an ultrasonic transducer assembly, a conformable ultrasonic transducer has a piezoelectric layer and electrodes able to conform to curved surfaces, and a clamp for pressing the transducer into ultrasonic contact with a curved surface. Conformability is ensured with a thin, porous piezoelectric layer and suitable electrical conductors and insulators. The ultrasonic transducer may operate without further thermal shielding under harsh environments and/or at high temperatures.

FIELD OF THE INVENTION

The present invention relates to an ultrasonic sensing assembly andsystem that is particularly useful for the monitoring of curved objects,including those that operate at high temperatures.

BACKGROUND OF THE INVENTION

Corrosion, erosion, fatigue, creep are examples of degradationmechanisms that limit the life time of structures and cause significanteconomic impact on many industries. The prediction of life time ofstructures is often not precise enough and inspection methods areregularly applied to structures to determine its health condition.Ultrasonics is one of the most valuable non-destructive testing methodsto evaluate the condition of structures exposed to degradationmechanisms.

Structural health monitoring (SHM) of components of power plants, oil &gas and aerospace industries, such as pipes and other vehicle partshaving respective contoured surfaces is desirable, but tricky. Access tothe structural parts to be inspected may be difficult due, for example,to safety concerns for inspectors, or to a limited access to thestructure surface due to thermal insulation, adjacent mechanisms,electrical, pneumatic or hydraulic control lines, etc. Furthermore, onceaccess is provided, installing a sensor in a way that provides adequatecontact between a piezoelectric material and the component to be tested,may be difficult. Also, the inspection may require the shutdown of arunning process. Therefore permanently or semi-permanently installedtransducers are often preferred, especially in transducers that permit astate of the structure to be sensed at any time (on demand) byelectronic request. The time between inspections is typically chosen inorder to provide accurate prediction of the remaining life time of thestructures. Therefore permanently attached transducers with easyelectronic interrogation of the sensor are in demand to make shorter andless costly interrogation of the condition of the structure.

Sensors for structural health monitoring are often required to operatein harsh environments as for example, at high temperatures. Thereforethe permanently attached transducers may also be required to maintainits performance for long periods of time, at high temperatures. Hightemperatures transducer configurations have been proposed using a delayline and cooling of transducers as for example, in U.S. Pat. No.7,185,547 to Baumoel, entitled ‘Extreme Temperature Clamp-on UltrasonicFlowmeter Transducer’. The delay lines and cooling significantly limitsthe value of such transducers for widespread structural healthmonitoring. Therefore it is required to develop transducers composed ofmaterials that can maintain a significant proportion of its essentialproperties at high temperatures.

Similar techniques have been used to separate ultrasonic transducersfrom high temperature surfaces and the separation, though perceived tobe required for operation of the sensor, impairs the use of the sensor,and occupies a lot of space around the component.

Other examples of patents in this field are: U.S. Pat. No. 3,781,576, toRunde, et al., entitled High temperature Ultrasonic Transducer; U.S.Pat. No. 4,392,380, to Caines entitled High Temperature Pressure CoupledUltrasonic Waveguide; U.S. Pat. No. 4,567,770 to Rumbold et al.,entitled Ultrasonic Transducer Apparatus and Method for High TemperatureMeasurements; U.S. Pat. No. 4,738,737 to Runde et al., entitled Methodof Using a High Temperature Ultrasonic Couplant Material; U.S. Pat. No.4,783,997, to Lynnworth entitled Ultrasonic Transducers for HighTemperature Applications; U.S. Pat. No. 5,325,012 to Sato et al.,entitled Bonded Type Piezoelectric Apparatus, Method for Manufacturingthe Same and Bonded Type Piezoelectric Element; U.S. Pat. No. 5,886,456to Stubbs et al., entitled Ultrasonic Transducer and UltrasonicDetection and High Temperature Processing Systems Incorporating Same;and U.S. Pat. No. 7,743,659 to Kearns et al., entitled Structural HealthMonitoring (SHM) Transducer Assembly and System.

‘Flexible Ultrasonic Transducers’ by Kobayashi, M., Jen, C. K, andLevesque, D., IEEE Trans. on Ultrasonics, Ferroelectrics and FrequencyControl, vol. 53, no. 8, August 2006 teaches that the flexibleultrasonic transducers (FUTs) are applicable to in-situ SHM, NDT andon-line diagnosis. To demonstrate the flexibility and operability ofsuch FUTs when flexed, one experiment was performed on a thick pipe atroom temperature and at elevated temperatures. As shown in FIG. 1, andFIG. 2, a viscous oil ultrasonic couplant was applied on the pipe at thelocation of testing, it was covered with a 75 micron stainless steelfoil, and a PZT piezoceramic film, which was topped with a silver paste,to serve as an electrode. The pipe itself served as the ground. Amechanical holder is provided to maintain the FUT in place.

While the mechanical holder of Kobayashi et al. encircled a pipe, it wasnot a clamp for the FUT as the term is used in the present art, and theactive area of the FUT is substantially free of pressure as there is awide opening in the clamp surrounding the FUT, as is shown in FIGS. 1and 2. The purpose of the clamp is just to prevent slipping of the FUTon the oiled, rounded, surface. Also in this previous art, theelectrical connections are made by spring-loaded pins that are notpractical for real industrial applications.

Other previous art that uses some kind of flexible transducers like U.S.Pat. No. 5,166,573 to Brown, for example, which teaches how to producepolymer-base FUTs and flexible UT arrays, but does not teach a practicalassembly to attach to permanently monitor structures. Also, as thepiezoelectric layers of these transducers are polymer-based, they areinherently incapable of high temperature applications.

Accordingly, there is a need for improved ultrasonic transducerassemblies to perform structural health monitoring that can bepermanently installed in curved objects, can maintain performance forlong periods of time, including at high temperatures and harshenvironments, and can allow easy and automated electronic interrogationof the condition of the structure.

BRIEF SUMMARY OF THE INVENTION

A transducer assembly is provided for structural health monitoring, andthe like, that improves the durability and signal quality while avoidingdifficulties characterized with the prior art. While one substantialadvantage of using a clamp is that substantially higher pressures can beapplied, allowing a greater variety of couplants to be used for highertemperature applications, for example, the clamp with a flexiblepiezoelectric film has advantages even in low temperature applicationswithout any couplant, improving durability of the transducer assembly,avoiding debonding, and improving signal quality and strength.

Accordingly, an ultrasonic transducer assembly is provided that includesa piezoelectric film that is able to conform to curved surfaces, atleast a flexible electrode adjacent to a top surface of thepiezoelectric film, to make the piezoelectric film able to act as anultrasonic transducer, a flexible insulating layer covering the topelectrode and at least part of a first electrical connector extendingfrom the top electrode to an electronic control, the insulating layerhaving a shape and size to substantially surround a section of acomponent to be monitored, and a permanent or semi-permanent clampadapted to apply at least a 0.2 MPa compressive stress on a region ofthe component aligned with the top electrode. The clamping of the FUT inthe region aligned with the top electrode ensures that the stress isapplied where the contact is needed to improve ultrasonic couplingbetween the FUT and the section of the component.

The transducer assembly is preferably flexible so that it may be clampedto curved surfaces, such as pipes, or pipe fittings (e.g. elbows,couplers, pipe joints, etc.) and other shaped components, especiallythose components that have sections that include convex surfaces. Thematerials chosen for construction of the transducer assembly may retainsufficient structural, electrical, and chemical integrity under severeharsh environments, such as high temperatures, making the assemblysuitable for high temperature operation. For example, the piezoelectricfilm may have a composition consistent with fabrication using one ormore layers of a mixture of a piezoelectric powder and organicprecursors of dielectric and/or piezoelectric material. The resultingpiezoelectric film may therefore have a level of porosity that improvesflexibility, resistance to thermal shock and ultrasonic bandwidth.

The transducer assembly may further comprise an ultrasonic couplinglayer (or couplant) composed of an ultrasonic transmitting material thatmakes an intimate physical contact with the transducer assembly, formaking intimate physical contact with the component to be monitored. Thecouplant may comprise a high temperature paste or liquid, or a softmetal, such as aluminum, gold, tin, zinc or other alloys known to theart of soldering and brazing. A foil of a soft (or temperature softened)metal may be particularly preferred for longevity of the couplantsystem. Some foils (such as gold) require greater stress to ensureintimate physical contact. Accordingly, if a metal foil couplant isused, the clamp may be adapted to apply at least 1 MPa compressivestress, or at least 10 MPa compressive stress. The clamp may be adaptedto apply an initial compressive stress greater than 1 MPa to plasticallydeform the metal foil, and a far lower compressive stress thereafter formaintaining the intimate physical contact. The metal foil may have beenstrained by a much greater compressive stress than the clamp, in whichcase the clamp may serve only to maintain intimate physical contactbetween the assembly and the component.

The assembly may further comprise a bottom electrode adjacent thepiezoelectric film on a surface opposite the top electrode. The bottomelectrode may be electrically coupled to the component, which issufficiently conductive to serve as a ground for the flexible ultrasonictransducer, or coupled to the electronic control by a second electricalconnector that is insulated from the first electrical connector. Thebottom electrode may also serve as the clamp.

The insulating layer may include a conductive path between top andbottom insulations, with a via through the bottom insulation forproviding electrical contact between the conductive path and the topelectrode. The insulating layer may be formed of mica or polyimide.

The piezoelectric layer may be bonded to the component to be monitoredby a ceramic binder made from organic precursors of a piezoelectricand/or dielectric ceramic.

A protective layer may surround the insulating layer. The clamp may be aband that serves as the protective layer. The clamp may be a tube clamp,comprising a deformable band for surrounding the section, formed ofmetal or a fibreglass textile, and may have a tensioning mechanism witha spring or spring washer to maintain a constant tension under differentthermal conditions. More deformable band materials have superiorconformability making them suited to components having more complexgeometry.

A plurality of separate piezoelectric films may be spaced along theinsulating layer to provide a transducer array, each piezoelectric filmbeing similar. The separate piezoelectric films are independentlyelectronically addressable by the electronic control, or are commonlyelectronically controlled.

Accordingly a method is provided for producing a transducer assembly.The method comprises providing a flexible ultrasonic transducer,including at least a top electrode adjacent to a flexible piezoelectricfilm; bonding said top electrode to an insulating layer, the insulatinglayer having a shape and size to substantially surround a section of acomponent to be monitored, providing insulated electrical connectionfrom the top electrode to an electronic control, and providing apermanent or semi-permanent clamp adapted to apply at least a 0.2 MPacompressive pressure on a region of the component aligned with the topelectrode.

The method may further comprise preparing a part of a surface of thesection of the component; applying a couplant to the part of the surfaceto provide intimate physical contact between the couplant and thesurface; and mounting the previously assembled layers to the couplant toprovide intimate physical contact between the couplant and the flexibleultrasonic transducer. If the couplant is in the form of a metal foil,the mounting may comprise applying an initial compressive stress greaterthan 1 MPa to plastically deform the soft metal foil. Alternatively,applying the couplant may comprise applying an adhesive material, suchas a polymer based glue, silver paste, ceramic cement, glass known inthe art of adhesive bonding.

If the couplant or the component is not electrically conductive, themethod may further comprise applying a bottom electrode and insulatedconductors from the bottom electrode to the electrical control. Thebottom electrode may be a titanium, aluminum or stainless steel foil, orother metal or metalized foil.

Providing the flexible ultrasonic transducer may comprise applying oneor more layers of a mixture of a piezoelectric powder and organicprecursors of dielectric and/or piezoelectric material; heat treatingthe applied layers; and poling the applied layers to produce thepiezoelectric film, and may further comprise applying the top electrodeas a silver or gold paste or by thin film deposition of a conductivemetal, such as gold, silver, platinum or aluminum. Alternatively theflexible ultrasonic transducer may be provided as a separate component,or may be integrated with the insulating layer.

The electrical control may comprise an electric pulse generator, anelectric signal detector, an electrical analog to digital signalconverter, a digital memory, and a communications interface forexchanging digitized signals by conductor or wirelessly.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention can be understood in more detailfrom the following descriptions taken in conjunction with theaccompanying drawings in which:

FIG. 1 shows a perspective view of a clamp-on multi-element transducerarray according to an embodiment of the present invention;

FIG. 2 shows a partial cross-sectional view of a single-elementtransducer assembly according to an embodiment of the present invention;

FIG. 3 shows a partial cross-sectional view of a multi-elementtransducer assembly according to an embodiment of the present invention;

FIG. 4A shows a partial cross-sectional view of an example lay-upconfiguration for forming the transducer assembly according to anembodiment of the present invention;

FIG. 4B shows a partial cross-sectional view of another example lay-upconfiguration for forming the transducer assembly according to anembodiment of the present invention;

FIG. 4C shows a partial cross-sectional view of another example lay-upconfiguration for forming the transducer assembly according to anembodiment of the present invention; and

FIG. 4D shows a partial cross-sectional view of another example lay-upconfiguration for forming the transducer assembly according to anembodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following detailed description of embodiments refers to theaccompanying drawings, which illustrate specific embodiments of theinvention. This invention may, however, be embodied in different formsand should not be construed as limited to the embodiments set forthherein.

FIG. 1 is a schematic illustration of an example of the embodiment ofmulti-element ultrasonic transducer assembly for monitoring structuralintegrity. In this example a tube clamp 18 is used as a mechanicallyconstraining layer. It embraces all other layers of the assembly andmakes a robust attachment to the component to be monitored 10represented by a tube in this example. Tube clamp 18 ensures goodphysical contact between layers of the transducer assembly whereultrasound need be transmitted. The transducer assembly is mounted on apipe. Other common examples of components to be monitored include pipefittings, and pressure vessels among others. In this example, aconnection box 20 is used to connect electrical conductors of thetransducer assembly array to an external multi-conductor cable 21 thatis to be connected to an electronic control 22. In another embodiment,each conductor of the external multi-conductor cable 21 continues toeach element of the transducers and the connection box 20 is notnecessary.

FIG. 2 is a schematic illustration of a cross-sectional detailed view ofa part of an ultrasonic transducer assembly in accordance with anembodiment of the present invention, having a single piezoelectricelement. It will be noted that the extreme thinness of some of thelayers make them ill suited for scaled representation. For example, theelectrodes may be hundreds of nanometers thick, the piezoelectric layersand electrical foils may be microns thick, insulating layers may behundreds of microns thick, and the tube clamp band may be a fewmillimetres thick or thinner, in typical examples.

In this embodiment, a piezoelectric film 13, located between a topelectrode 14 and a bottom electrode 12, is driven by an electricexcitation carried by electric conductors 16 and 16′. The piezoelectricfilm 13, in this embodiment, has preferably some flexibility in order tobend to fit curved objects, even if it was formed by in-situ deposition.The piezoelectric film 13 preferably has some internal damping to avoidthe need for a backing, while still being able to excite and detectshort ultrasonic pulses. If the transducer assembly is to be used tomonitor components at high temperature, it is preferable that thepiezoelectric film 13 show good resistance to thermal expansion of bothtop electrode 14 and bottom electrode 12. The piezoelectric layer 13 maybe made of materials that maintain piezoelectricity at hightemperatures. These properties for a piezoelectric film can be obtained,for example, by producing it by the method known in the art as thesol-gel route. Both the top electrode 14 and bottom electrode 12 arepreferably thin compared to the ultrasonic wavelength in order to avoidspurious echoes. Thin electrodes have also, in general, the advantage ofbeing flexible, which allows them to be fitted to curved surfaces.Electric conductors 16,16′ connect the top and bottom electrodes to theelectronic control 22, and are electrically separated from otherelectric conductive parts of the assembly by the top insulator 17 andbottom insulator 15. The connection to the bottom electrode 16′, oftenreferred to as the ground, can be connected to the component 10,provided that it is electrically conductive and the bottom electrode isconnected to the component 10. In some embodiments, it may be preferableto use a connection box 20 between the electric conductors 16,16′ of thetransducer assembly and the electronic control 22. In such cases,appropriate conductive cables 21 connect the electronic control 22 tothe connection box 20. The electrical conductors 16,16′ can be in theform of wire or a foil strip or any other electrical conductor meansknown in the art. The electric insulation layers 15 and 17, arepreferably of a flexible material, to conform to a component with curvedsurfaces, while maintaining its properties at high temperatures (if thecomponent 10 is monitored at high temperature). Materials that are knownto be suitable for insulator layers include mica, fibreglass textilesand polyimide, among others. To hold this ultrasonic transducer assemblylayers 12-17 to the component 10, the clamp 18 is provided. The clamp 18applies a stress that keeps the layers in intimate physical contact witheach other and the component 10. At the same time, the clamp 18 protectsthe assembly against external aggression.

The ultrasonic excitation generated by the piezoelectric layer 13 istypically better transmitted to the component 10 via a coupling layer11. The coupling layer 11 may be a liquid, gel, or solid and should bepreferably thin compared to the wavelength of ultrasonic wave generatedby the piezoelectric layer. Some materials that may be used as ancoupling layer include ultrasonic liquid couplants, polymeric adhesivematerials, silver and gold paste, soft metal foils like gold, aluminum,zinc and tin as well as low melting temperature metals like aluminum,zinc, tin and other alloys known in the art of soldering and brazing.

To facilitate installation of the ultrasonic transducer assembly of thepresent invention to component 10, the layers 12 to 18 may be preferredto be preassembled in a manufacturing facility. The preassembledtransducer is them installed to the component to be monitored 10 afterpreparing its surface, if needed, and applying the coupling layer 11.Some coupling layers solutions may need a thermal treatment to obtainthe desired properties, and some operate only at certain temperatures.

A multi-element ultrasonic transducer assembly can also be of interest.FIG. 3 shows an example of an embodiment, which is similar to aone-element configuration shown in FIG. 2 but have many elements alongthe component 10. The electrical conductor 16 in this embodiment connectthe top electrode 14 of each element of transducer subassemblyindependently of the connection box 20 allowing independent ultrasonicoperation for each element. The bottom electrode connection 16′, orground connection, is common for all elements. It will be noted thatindependently addressable elements may be desired for differentpurposes, and parallel insulated conductors between the top and bottominsulating layers 15,17 can be provided.

There are many configurations for layers of the ultrasonic transducerassembly of this invention that can conform to curved surfaces of thecomponent to be monitored. The transducer assembly configuration shownin FIG. 4A as an enlarged cross-sectional view, is similar to thosealready described in FIG. 2 and FIG. 3 with a coupling layer 11, makingintimate contact to the component 10 and the bottom electrode 12. Thepiezoelectric layer 13 is in intimate physical contact with bottomelectrode 12 and the top electrode 14. The electrical conductor 16 is inconductive contact with the top electrode 14 at one of its ends througha hole in the bottom insulator 15, and at the other of its ends, at theconnection box 20 or the electronic control 22 (depending on the controlarrangement chosen). Two insulator layers, the bottom insulator layer 15and top insulator layer 17 may be used to insulate the electricalconductor 16 from other conductive parts of the assembly.

Alternatively a single top insulator could be used, with an alternativeinsulation provided, to the extent needed. Clamp 18 keeps the layersthat need intimate physical contact together, and at the same time, mayprotect the assembly against external aggression.

Another transducer assembly configuration is shown in FIG. 4B with anenlarged cross-sectional view. Similar reference numerals denoteanalogous elements, and their description is not repeated herein. Inthis case, the piezoelectric layer 13 is in intimate contact with thecomponent 10. This intimate contact can be obtained by the fabricationof the piezoelectric film 13 directly on the surface of component 10 oralternatively by bonding a piezoelectric film to the component to bemonitored with a binder with similar characteristics to thepiezoelectric layer. In this embodiment the bottom electrode is providedby the component 10, and electrical connection with this ground plane isprovided to the connection box or electrical control (not shown).

FIG. 4C schematically illustrates an enlarged cross-sectional view of atransducer assembly in which the clamp 18 is also bottom electrode 12.In this example, the piezoelectric layer 13 is in intimate contact withthe clamp 18. This configuration may be particularly useful wherein thechosen coupling layer 11 needs a higher stress mechanical constraint tomake intimate physical contact with the component 10 to allow efficienttransmission of the ultrasonic waves, e.g. if the surface of thecomponent is particularly rough, or the couplant 11 is stiff. Theremainder of the flexible ultrasonic transducer may be the same asabove, but it may further be desirable to provide a protective layer 19,to surround the top insulating layer 17 to protect the assembly againstexternal aggression. Protective layer 19 need not apply any appreciablepressure to the insulating layer 17.

FIG. 4D schematically illustrates an enlarged cross-sectional view of atransducer assembly having no couplant 11 other than the bottomelectrode 12, that may be a soft metal foil.

1. An ultrasonic transducer assembly useful for monitoring a componenthaving a curved outer surface, the transducer comprising: apiezoelectric film having top and bottom surfaces, the film having aflexibility to conform to said curved outer surface and being orientedto excite and detect ultrasonic pulses in a direction orthogonal to thefilm bottom surface; and a top electrode adjacent to the top surface ofthe piezoelectric film to make the piezoelectric film able to act as anultrasonic transducer in said direction orthogonal to the film bottomsurface when a voltage is applied to said top electrode.
 2. A transducerassembly according to claim 1, further comprising: an electricalconnector extending from the top electrode.
 3. A transducer assemblyaccording to claim 1, further comprising: a flexible insulating layercovering the top electrode and at least part of the electricalconnector, the insulating layer having a shape and size to substantiallysurround a section of a component to be monitored.
 4. A transducerassembly according to claim 1, further comprising: a clamp configured toapply compressive stress on a region of the component, the clamp beingaligned with the top electrode.
 5. The transducer assembly of claim 1wherein: the transducer assembly is flexible, and the clamp comprises aband that, when tensioned, causes the assembly to conform to a convexsurface of the section of the component.
 6. The transducer assembly ofclaim 1, further comprising the component, which has the form of a pipeor a pipe fitting; wherein the transducer assembly is positioned on thecomponent curved outer surface with the clamp holding the transducerassembly to said component curved outer surface.
 7. The transducerassembly of claim 1, further comprising: an ultrasonic coupling layerhaving top and bottom surfaces, said coupling layer being composed of anultrasonic transmitting material making intimate physical contact withthe transducer assembly at said top surface, and for making intimatephysical contact with the component at said bottom surface.
 8. Thetransducer assembly of claim 7, wherein the ultrasonic transmittingmaterial comprises a high temperature paste or liquid, or a soft metal.9. The transducer assembly of claim 7, wherein: the coupling layercomprises a metal foil.
 10. The transducer assembly of claim 6, furthercomprising: a bottom electrode electrically coupled to the component,which is conductive to serve as a ground for the flexible ultrasonictransducer.
 11. The transducer assembly of claim 3, wherein theinsulating layer comprises: a conductive path between top and bottominsulations, with a via through the bottom insulation for providingelectrical contact between the conductive path and the top electrode.12. The transducer assembly of claim 3, further comprising: a pluralityof said piezoelectric films separately spaced along the insulating layerto provide a transducer array.
 13. The transducer assembly of claim 4,wherein: the transducer assembly is flexible; and the clamp comprises atube clamp comprising a deformable band for surrounding said section,formed of metal or a fibreglass textile.
 14. The transducer assembly ofclaim 4, wherein the transducer assembly is flexible, and the clampcomprises a tensioning mechanism having a spring or spring washer tomaintain a constant tension under different thermal conditions.
 15. Thetransducer assembly of claim 1, further comprising an electronic controlin electrical communication with the top electrode.
 16. The transducerassembly of claim 15, wherein the electrical connector is a firstelectrical connector, and further comprising: a second electricalconnector that is insulated from the first electrical connector; and abottom electrode electrically coupled to the electronic control by saidsecond electrical connector.
 17. The transducer assembly of claim 15,further comprising said component, and wherein a surface of thecomponent serves as a bottom electrode of the flexible ultrasonictransducer, and includes an electrical connection to the electricalcontrol.
 18. The transducer assembly of claim 17, wherein thepiezoelectric layer is bonded to the component to be monitored by aceramic binder made from organic precursors of a piezoelectric and/ordielectric ceramic.